2012 Apec 135 Coupled Electromagnetic and Thermal Analysis Ferrite Core Electronic Planar Transforme

2011 ANSYS, Inc.
February 29, 2012 1

Coupled Electromagnetic and
Thermal Analysis of Ferrite Core
Electronic Planar Transformer

Mark Christini, P.E.
Technical Manager
ANSYS, Inc
2011 ANSYS, Inc. February 29, 2012 2
Introduction
Maxwell 3D Eddy Current and
Electrostatic Simulation
ANSYS Mechanical Thermal
Simulation
2-way Thermal Coupling back to
Maxwell
Simplorer System Simulation using
Maxwell State Space Dynamic
model
Summary
Outline
Coupled electromagnetic-thermal analysis of a ferrite core
electronic planar transformer
Magnetic simulation done at fundamental frequency =
100kHz with harmonics up to 5MHz
All sources of losses considered including: eddy current, skin,
and proximity losses in the windings as well as eddy current
and hysteresis losses in the ferrite core
Losses are directly coupled into an ANSYS Mechanical
Thermal simulation in order to determine temperature rise
using element by element coupling
Temperatures fed back to Maxwell for material changes
System simulation done inside of Simplorer using dynamic
state space frequency dependent model
Introduction
Coupled Electromechanical Design Flow

Simplorer
System Design

PP := 6
ICA:
A
A
A
GAIN
A
A
A
GAIN
A
J PMSYNC IA
IB
IC
Torque J PMSYNC IA
IB
IC
Torque
D2D
Maxwell 2D/3D
Electromagnetic Components

PExprt
Magnetics

RMxprt
Motor Design

Q3D
Parasitics

ANSYS
Mechanical
Thermal/Stress

Model order Reduction
Co-simulation
Field Solution
Model Generation
ANSYS CFD Fluid
Flow
FEA Adaptive Meshing
2D Transformer Model
2D Transformer Mesh
In 2D, finite
elements
are
triangles
3D Transformer Model
3D Transformer Mesh
In 3D, finite
elements
are
tetrahedra
Electric Field effects:
varying dielectric permitivities
varying dimensions and shape
3D field effects
Magnetic effects:
nonlinear materials
frequency dependent materials
temp dependent materials
eddy currents
proximity effects
eddy and hysteresis losses
time diffusion of magnetic fields
transient excitations
Transformer Design Challenges
Electrical Magnetic Fluid Mechanical Thermal Acoustic
Circuit
System
Component

ANSYS Workbench
ANSYS Simplorer
Mixed-Signal Multi-Domain
System Simulator

Model Order Reduction &
Cosimulation
ANSYS Comprehensive Solution

Workbench Coupling Technology
Electromagnetic Thermal Stress System
Ferrite PQ Core
Primary turns = 4
Secondary turns = 2
Insulation layers between conductors
Fundamental Frequency = 100kHz

Electronic Planar Transformer
24mm
7mm
14mm
Load case with Ipri = 50A
and Isec = 80A
Unbalanced A-turns for
core excitation

Maxwell 3D Source Setup
Ferrite Core Properties
Frequency dependent permeability and imaginary permeability
Use Simplorer Sheetscan utility to grab permeability data points
Sheetscan
Datasheet
Required inputs for Maxwell are real permeability and
loss tangent
Loss tangent based on series equivalent model
Temp = 0 C
Frequency Dependent Core Properties in
Maxwell
s
s
s
s
s
L
R
e
o = =
'
"
frequency perm perm_imag loss tangent
100000 1939 6 0.0032
200000 1977 13 0.0068
300000 2015 22 0.0110
400000 2052 35 0.0173
500000 2090 51 0.0244
600000 2165 79 0.0363
700000 2281 119 0.0522
800000 2322 174 0.0750
900000 2446 264 0.1078
1000000 2533 336 0.1326
1500000 2581 998 0.3869
2000000 2029 2101 1.0351
3000000 828 2178 2.6306
4000000 227 1626 7.1618
5000000 97 1093 11.2199
6000000 61 663 10.8398
7000000 47 424 8.9644
8000000 39 327 8.3658
9000000 34 271 7.9437
10000000 31 228 7.4132
Datasets used to define properties vs. frequency:
Relative Permeability = pwl($perm,Freq)
Magnetic Loss tangent = pwl($losstan,Freq)
Relative permitivity = 12
Conductivity = 0.5 (S/m)

Core Material Properties - Inputs
Use named expression in calculator to verify the
real and imaginary permeability
Use report to plot and loss tangent vs. frequency

Core Material Properties - Outputs
Real permeability -
Num > Vector > 1,0,0
Material > perm > multiply
complex > real > mag
constant > mu0 > divide
Loss tangent
= /
0.00 1.00 2.00 3.00 4.00 5.00
Freq [MHz]
0.00
500.00
1000.00
1500.00
2000.00
2500.00
3000.00
m
u
_
r
e
a
l
_
e
v
a
l
0.00
2.00
4.00
6.00
8.00
10.00
12.00
l
o
s
s
_
t
a
n
g
e
n
t
Maxwell3Ddesign2 Permeability and Loss Tangent ANSOFT
Curve Inf o
mu_real_eval
Setup1 : LastAdaptive
Phase='0deg'
loss_tangent
Phase='0deg'
Real permeability -
Num > Vector > 1,0,0
Material > perm > multiply
complex > imag > mag
constant > mu0 > divide
Temperature Settings in Maxwell
Initial temperature
= 22 C
Core and windings
have temp
dependent
materials
Temperature dependent copper conductivity
for 2-way coupling to Maxwell
)) 22 ( * 0039 . 0 1 (
1
+
=
Temp
o
Initial Conductivity at 100kHz, 22 deg C
Conductivity = 5.8e
7
(S/m)
Conductivity is constant throughout winding
Temperature dependent ferrite permeability
for 2-way coupling to Maxwell
2-way coupling for temperature dependent
permeability
0
1000
2000
3000
4000
5000
-50 0 50 100 150 200 250
temp (C)
Permeability
deg C perm
perm
modifier
-50 1247 0.73
-25 1440 0.85
0 1700 1.00
25 2031 1.19
50 2442 1.44
74 2982 1.75
89 3252 1.91
100 3368 1.98
113 3483 2.05
125 3522 2.07
137 3560 2.09
149 3586 2.11
162 3650 2.15
175 3753 2.21
183 3869 2.28
189 3985 2.34
191 4113 2.42
194 4267 2.51
195 4370 2.57
197 4524 2.66
200 4576 2.69
202 4524 2.66
204 4422 2.60
205 4023 2.37
206 2494 1.47
209 514 0.30
211 180 0.11
213 77 0.05
216 39 0.02
221 13 0.01
225 13 0.01
0.00
0.50
1.00
1.50
2.00
2.50
3.00
-50 0 50 100 150 200 250
Permeability modifier
Initial Permeability at 100kHz, 22 deg C
Imaginary Permeability Real Permeability
Current Density at 100kHz, 22 deg C
Load case with Ipri = 50A
and Isec = 80A

Magnetic Flux Density at 100kHz, 22 deg C
Winding losses
considers skin and
proximity effects
Winding Eddy Current Loss Density at
100kHz, 22 deg C
Core Loss Density at 100kHz, 22 deg C
Hysteresis Loss Ohmic Loss
( ) dV H B P
vol
hysteresis
}}}
- =
*
Im
2
1

e ( ) dV J J P
vol
eddy
}}}
- =
*
Re
2
1

o
Freq [kHz]
core_hyster_loss
Phase='0deg'
core_eddy_loss
Phase='0deg'
1 10.000000 0.001082 0.001897
2 100.000000 1.211527 0.191875
3 500.000000 44.428733 5.032800
core hyster eddy losses ANSOFT
Simulated Resistance, 22 deg C
0.01 0.10 1.00 10.00
Freq [MHz]
0.00
100.00
200.00
300.00
400.00
500.00
600.00
700.00
800.00
Y
1

[
o
h
m
]
Maxwell3Ddesign1
Resistance ANSOFT
Curve Inf o
Matrix1.R(pri_in,pri_in)
Matrix1.R(sec_in,sec_in)
Simulated Inductance, 22 deg C
0.01 0.10 1.00 10.00
Freq [MHz]
5.00
10.00
15.00
20.00
25.00
30.00
35.00
40.00
45.00
Y
1

[
u
H
]
Maxwell3Ddesign1
Inductance ANSOFT
Curve Inf o
Matrix1.L(pri_in,pri_in)
Matrix1.L(sec_in,sec_in)
Simulated Capacitance
Use DC conduction solver to assign +1V and
-1V to coils and on core
Workbench Coupling
Maxwell 3D Eddy
Current calculates
losses and couples
directly to ANSYS
thermal
Maxwell 3D
Electrostatic calculates
capacitances between
winding and core
Maxwell 3D Eddy
Current calculates R,L
vs. frequency and
inports directly into
Simplorer via the
State-space dynamic
link

Workbench Coupling
Engineering Data allows materials to be chosen including thermal conductivity
Workbench Coupling
Workbench
geometry
imported
directly into
Workbench
Appropriate
materials
can then be
assigned
Workbench Coupling
Workbench mesh is
different than Maxwell
3D mesh
Set maximum element
size = 0.5mm
Workbench Coupling
Fixed
temperature
cold plate
assigned to base
= 22 C
Convection
boundaries
assigned to
outer surfaces
of core and coils
= 5 W/m
2
- C

Workbench Coupling
Imported Loss Density on core and windings at
100kHz
Scaling Factor approximately ~ 1 indicates
sufficient mesh and excellent loss mapping from
Maxwell into Workbench
Exported loss
density from
Maxwell 3D
Imported loss density
into Workbench
Ferrite Core Transformer Temperature at
100kHz
Temperature range from 22182 deg C
Export temperature back to Maxwell
Re-solve in Maxwell with actual temp from
Workbench
Message:
Solving with
temperature
data from
ANSYS
Updated Copper Conductivity with 2-way
coupling
Initial conductivity at 22C
is uniform = 5.8e
7
(S/m)

As temp increases, conductivity
decreases
Final conductivity at operating
temperature = 3.5e
7
to 4.7e
7
(S/m)

Initial Conductivity
Final Conductivity
Updated Loss density with 2-way coupling
As temp increases, conductivity
decreases and loss density
increases
Initial Loss Density at 22 C
Final Loss Density
Increased Loss Density at
operating temp
Matlab
Simulink

Simplorer Architecture
Simulation Data Bus/Simulator Coupling Technology
Co-Simulation
Circuits:
States:
Electromagnetic
(FEA)
Mechanical
(FEA)
Model Extraction: Equivalent Circuit, Dynamic State
Space, Impulse Response Extracted LTI, Stiffness Matrix
Fluidic
(CFD)
VHDL-AMS
IF (domain = quiescent_domain)
V0 == init_v;
ELSE
Current == cap*voltage'dot;
END USE;
Matlab

Real Time
Workshop
C/C++
User Defined
Model
ANSYS
MBD
ANSYS
Maxwell
Blocks:
Thermal
(FEA)
Simplorer System Simulation
Maxwell 3D Frequency Sweep
Select appropriate Maxwell
3D design with
frequency sweep
Imported
frequency
dependent R,L
model (state-
space)
Imported
capacitance
model
Apply
appropriate
sources and
loads
Maxwell 3D determines R, L and loss components
(eddy current, hysteresis, proximity, skin) at multiple
frequencies as well Capacitance
Using Workbench, Maxwell loss densities are
coupled to ANSYS Mechanical for temperature rise
calculation
Resulting temperature rise can be coupled back into
Maxwell to change material properties such as
permeability and conductivity and determine
thermal operating point and calculate higher losses
Maxwell 3D can export a frequency dependent
transfer function using Dynamic State Space coupling
inside of Simplorer to allow for a complete system
simulation
Conclusions

2012 Apec 135 Coupled Electromagnetic and Thermal Analysis Ferrite Core Electronic Planar Transforme

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2012 Apec 135 Coupled Electromagnetic and Thermal Analysis Ferrite Core Electronic Planar Transforme

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2011 ANSYS, Inc.

February 29, 2012 1

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